technical specification of rail borne telescopic crane for

of 31 Rail Borne Telescopic Crane (new) June-2020

Technical Specification of Rail Borne Telescopic Crane for Changing Turn out

Assembly for B.G.(1676 mm)

(Specification No. TM/HM/RBTC/464 of 2020)

1.0 GENERAL 1.1 In mechanised laying process of turn outs, the points and crossing shall be pre-

assembled in assembly workshop/yard/depot to preserve track geometry as per design and it will be transferred to work site by switch transportation wagon (STW). A crane is needed to load the newly assembled P&C (turn out) on STW, removal of existing turn out from track, unloading from STW and laying of newly assembled turn out and loading of the old turn out on STW without infringing any obstruction like OHE mast, signal posts, location box etc. This specification covers the requirements for design, manufacture, supply and delivery including commissioning into service of self-propelled Rail Borne Telescopic Crane for Changing Turn out Assembly on Broad Gauge system of the Indian Railways. Self-propelled Rail Borne Telescopic Crane for Changing Turn out Assembly is hereafter referred to as rail-crane. The rail-crane is to be used mainly for loading/unloading of assembled Turn outs on wagon as well as replacing old turn out with new one at work site. It may be used for bridge works as per the capacity and capability of the rail crane.

1.2 Technical Specifications have been drafted to reflect the performance and quality requirements of the rail-crane in a neutral manner without bias to any specific manufacturer. Bidders are requested to carefully study the specification and assure that their rail-crane fully comply with these specifications. Thereafter, if a bidder feels that his rail-crane can substantially meet the performance and quality requirements of the specifications, but does not fully satisfy a particular system specification, he should mention the same in the statement of deviation from the technical specifications, giving the details how the functional requirements are going to be met with.

1.3 The bidder shall specify the make and model the offered rail-crane and furnish

detailed technical description of the same. System/sub-systems of the working mechanisms of the rail-crane, as per Para 3 in particular and all items of the specifications in general, shall be described in detail in the “Technical Description”, along with the sketches to show the manner in which the requirements of the specifications are accomplished by the rail-crane (model) offered.

1.4 Photographs and videos (for new manufacturers- detail drawing including General

Arrangement Diagram, all sub-assemblies etc. and technical write up of description and working of the Rail Crane) of the type of Rail Crane offered in working mode and technical literature shall be enclosed with the offer. The photographs shall also show close-ups of various working assemblies/systems and the full rail-crane. The tenderer shall also furnish a Compact disc (computer enabled) or DVD or USB showing the working of rail-crane under field conditions. Tenderer shall also submit the names of countries & Railways where the offered rail-cranes are working and where their working at site can be visited by Indian Railway officials.

1.5 The bidder shall be entirely responsible for the execution of the contract strictly in accordance with the terms and conditions of the specification not withstanding any approval, which RDSO or the Inspecting Officer may have given:

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• Of the detailed drawings prepared by the bidder.

• Of his sub- bidders for materials, components & sub-assemblies.

• Of other parts of the work involved in the contract.

• Of the tests carried out by the bidder/Sub- bidder or RDSO or the Inspecting

Officer.

2.0 DIMENSIONAL AND OPERATING REQUIREMENTS

2.1 The diesel-powered rail-crane shall be robust, reliable and suitable for working on

Indian Railways. The design and dimensions of the rail-crane components shall be to metric standards and shall comply with provision of Indian Railways Schedule of Dimensions–1676 mm Gauge (BG), revised, 2004 with the latest corrigendum and up to date correction slips issued. Quality assurance during manufacturing of the rail-crane shall be according to ISO-9001. The welding standard followed for manufacturing of rail-crane should conform to ISO:3834, EN:15085 or any other equivalent standard for welding railway vehicle and components. The manufacturer should specify the standard followed and certify that it meets the welding standard mentioned above. The rail-crane shall be suitable for working on straight, transition and curved tracks (up to 10 degree) on broad gauge (1676 mm) of Indian Railways.

2.2 The Rail Crane shall be a self-propelled bogie type vehicle with minimum 4 axles (2 bogies). Similarly the match-truck, used for accommodating boom/any component of the crane, should also be bogie type vehicle with minimum 4 axles (2 bogies). Normally the stocks running on IR are two axle or four axle (two bogies stocks) bogie stocks. For new combinations of axles/bogies prior technical approval of RDSO/IR shall be an important prerequisite and it shall be required before issue of the purchase order/finalization of the contract.

2.3 The profile of the Rail Crane longitudinally and in cross section during transfer as self propelled vehicle or towed in train formation shall be within the maximum moving dimensions shown in the Indian Railways Schedule of Dimensions–1676 mm Gauge (BG), revised, 2004 with the latest corrigendum and up to date correction slips issued. The maximum moving dimensions are enclosed in Annexure-I. The tenderer shall provide sketches of the Rail Crane in plan and shall give calculations for moving dimensions on 10° curve to show the extent of lateral shift at the ends, centre and any other relevant cross section and to show that the machine does not cause infringement while moving on a 10° curve at any cross section.

2.4 In the past Indian Railways have condoned certain infringements to the Indian Railways Schedule of Dimensions–1676 mm gauge (BG), revised, 2004 of such dimensions as Rigid wheel Base, Length of stocks, Distance apart of bogie centres and maximum height of floor above Rail level in certain track Rail Cranes after due consideration of their design features vis-à-vis safety and operation requirements of Indian Railways. However, condonation of an infringement in another track Rail Crane in the past does not by itself entitle the manufacturer to assume acceptance of the same in other track Rail Cranes by Indian Railways. Where an infringement to Indian Railways Schedule of Dimensions–1676 mm Gauge (BG), revised, 2004 with the latest corrigendum and up to date correction slips issued, is considered necessary by the manufacturer as intrinsic to the design of the Rail Crane for meeting the work performance requirements laid down in this specification while meeting the safety and operational requirements of Indian Railways, the condonation of the same may be permitted by Indian Railways. However, only those infringements which are acceptable shall be permitted.

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2.5 Adequate clearance shall be allowed so that no component/part of the rail-crane infringes the minimum vertical clearance of 91 mm from rail level while travelling on track up-to condemnation limit of wheel.

2.6 Wherever applicable, axle load shall be lesser than 20.32 t with minimum axle

spacing of 1.83 m while moving on track. Load per metre shall not exceed 7.67 t. Axle loads up to 22.82 tonnes and lower axle spacing may be permitted, provided the load combinations do not cause excessive stresses in the tracks & bridges of IR. Stresses in the tracks & bridges shall be calculated by IR/RDSO based on design data submitted by the firm as per (Annexure-VI) and decision of IR/RDSO shall be final in this regard.

2.7 It shall have a minimum wheel diameter of 914 mm (new wheel profile). However, lesser diameter up to 730 mm (new wheel profile) can also be considered, provided it meets the speed, riding quality criteria laid down in Clause 2.8 and rail wheel contact stresses for 72 UTS rails are within permissible limits. Forged wheels to Indian Railways profile shall be provided on the Rail Crane. The worn out wheel diameter based on the criteria of rail wheel contact stresses for various maximum axle loads are as under:

Permitted worn out wheel diameter should be specified by the manufacturer. The diameter of wheel for assessment of permitted axle load will be the worn out wheel diameter.

2.8 The new wheel profile of the rail-crane shall be as per Indian Railway standard drawing attached as Annexure-III which is titled as “WORN WHEEL PROFILE’

2.9 Wheels shall be conforming to Indian Railway Standard R-19/93 or European Standard EN13262 or any other equivalent standard (for product requirement) and design shall duly conform to European Standard EN 13979 or other equivalent standard. The supplier shall submit detailed design calculation along with material parameters at the time of supply of the Rail Crane.

2.10 The non-powered axles shall be conforming to Indian Railway Standard R-16/95 or

European Standard EN 13261(EA1N) or any other equivalent standard. The supplier

Maximum Axle load (tonne) Minimum worn out wheel

diameter (mm)

22.82 908

22.00 878

21.50 860

21.00 841

20.32 816

20.00 805

19.50 787

19.00 768

18.50 750

18.00 732

17.50 713

17.00 700

16.50 680

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shall submit detailed design calculation along with material parameters at the time of supply of the Rail Crane.

2.11 The powered axles shall be conforming to Indian Railway Standard R-43/92 or

European Standard EN 13261(EA4T) or any other equivalent standard (for product requirement). The design shall conform to EN: 13104 or any other equivalent standard. The supplier shall submit detailed design calculation along with material parameters at the time of supply of the Rail Crane.

2.12 It shall be capable of negotiating curves up to 100 curvature (175 m radius), super

elevation up to 185 mm, maximum cant deficiency 100 mm and gradients up to 1 in 33 in travel mode. The supplier shall specify the minimum attainable speed under the above limiting conditions.

2.13 It shall be capable of continuous operation during the varying atmospheric and

climatic conditions occurring throughout the year in India. The range of climatic conditions is as follows:-

Ambient temperature : -5° C to 55° C Altitude : Up to 1750 m above mean sea level Relative Humidity : Up to 100% Maximum rail temp : 70 o C

All the system components on the rail-crane, wherever possible, shall be covered by roof or other suitable sturdy covering so that the system & components vulnerable to moisture ingress are not adversely affected during rains and the Rail Crane is able to work continuously even during rains.

2.14 During transfer from one station to another, it shall be capable of travelling on its own at a speed of 40 25 kmph and at a speed of 100 kmph when hauled in a train formation as last vehicle. Since the Rail Crane is likely to cover long distances on its own power, the travel drive system should be robust to sustain these requirements during the life of the Rail Crane. The Rail Crane should be capable of hauling at least three nos. 8-wheeler Mechanised Wagon for transportation of Turn out assembly (180 ton approximately) at a maximum speed of not less than 40 kmph.

2.15 It shall be capable of working and travelling without requiring power block in electrified sections. On Indian Railways, 25 KV or 2x25 KV AC power supply is used for traction through an overhead wire at 5500 mm above rail level. On bridges and tunnels, the height is restricted to 4800 mm.

2.16 While working on double/multiple line sections, the crane must have a feature to avoid the counterweight infringing the adjoining track and it shall be possible to permit trains at full speed on that track. Minimum spacing of track is 4265 mm. The rail-crane or its any part shall not infringe adjoining track as per Indian Railways Schedule of Dimensions 1676 mm gauge (BG), reised-2004 with the latest corrigendum and up to date correction slips issued, during travelling or its operation including opening and closing of the work.

3.0 DESCRIPTION: 3.1 The rail-crane shall be self-propelled, bi-directional, fully rail borne bogie type vehicle

for loading/unloading of assembled turn outs on wagon as well as replacing old turn out with new one at work site.

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3.2 The crane shall be provided with lifting beam and tackles for gripping and lifting the turn out assembly at multi locations. Lifting beam shall be light weight and sufficient length to lift standard sections. For longer section mechanical extensions to be provided. The beam must be motorised and have a feature for longitudinal centre of gravity compensation. be telescopic and to The beam shall be suspended from the main lifting hook of the crane. The capacity of the hook shall not be less than that of maximum loading capacity of the crane.

3.3 The rail-crane shall be combination of crane and match-truck. The crane shall be telescopic, hydraulically operated and swivelling type. The match-truck shall be used to carry the boom of the crane as well as the lifting beam. The match-truck shall be coupled with the rail-crane.

3.4 The rail crane shall have electronic load movement limitation system which switch off the crane automatically when it reaches overload. There shall be provision of setting the maximum slew angle and boom height.

3.5 The rail crane shall have suitable system to automatically compensate the super elevation in curve track during normal working with full capacity. The tenderer in the offer shall confirm the possibility of propping the crane level on the maximum super elevated track.

4.0 WORKING MECHANISM: 4.1 The rail-crane shall be sturdy and robust in construction. The design and permissible

stress of structural portion of the crane shall comply with Group-M-4 with state of loading as “Moderate” as per IS:807-2006(Re-affirmed 2015). The platform shall be of chequered steel plates.

4.2 The rail-crane shall have telescopic boom of sufficient length reaching at least 15 m beyond buffer to reach the central position of T/outs segments loaded on the adjacent SRTW to perform loading, unloading and laying of turn out assembly sections of different sizes and rail sections as listed in Annexure-II. The load can be positioned freely by telescoping even under OHE with the boom in horizontal position, derricking and turning of the super structure. The crane shall manoeuvre around obstacles like OHE mast, signal posts platform etc.

4.3 The crane is intended to be used for:

i) Loading of turn out assembly as a whole or in segment as per the accommodating length of the transporting wagon at assembling site/workshop/depot.

ii) Eventually hauling the loaded wagon(s) to work site.

iii) Lifting the old turn out assembly as a whole or in segment placing the same temporarily on a suitable place at the vicinity of the worksite.

iv) Lifting the new Turn out assembly from wagon and laying it in the place of old

Turn out.

v) Lifting the old Turn out assembly and loading the same on the wagon.

vi) All the above operations for double slip/single slip diamond crossing.

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vii) Other miscellaneous work wherever required as per crane capacity.

4.4 Total time taken for completing the laying work of 1 in 12 Turn out (in suitable segments), as stated above, shall not exceed 2 hours. The time shall count from arrival of the crane at site of work and starting of the winding up of the crane after laying work.

4.5 For balancing the turn out assembly and to keep it in horizontal position with minimum sag during lifting and placing it is required to grip the Turn out at suitable locations. Suitably designed lifting beam with multiple griping tackles along the length of the beam shall be used. The beam shall be so designed that it can grip the entire Turn out or in segment wherever applicable at suitable locations.

4.6 The crane shall be hydraulically operated for all the operation like hoisting, derricking, swivelling, propping etc. It shall be possible to swivel the lifted load to 3600 smoothly without any jerk.

4.7 An effective slewing mechanism, capable of slew in either direction with maximum load on hook, even when the crane is on super elevated track or gradient shall be provided.

4.8 The slewing gear shall be provided with a powerful foot brake to ensure that the crane while under load will not slew of its own accord when working on steep gradient. The crane must have an automatic slewing rake that always apply when the operator releases the slewing control lever.

4.9 It shall be possible to start the operation of the crane at site within ten minutes of arrival. In case, the tenderer is not able to meet the above requirement, the set-up time shall be indicated by the tenderer and shall have to ensure the same during testing. Preferably the setting up and winding up time together shall not be more than 20 minutes.

4.10 The crane shall have minimum lifting capacity of 80 t at horizontal reach distance of at least 10 m radius at 360 degree from the centre of track at perpendicular direction. The tenderer shall submit the lifting capacities at various radii Suitable counter weight shall be provided at the tail to balance the crane while lifting and placing the load. The counterweight arrangement may be fixed type or telescopic type and shall have a feature for not infringe the adjacent track during working in multiple lines.

4.11 The arrangement of counterweight shall be such that only one support on the load side will be needed on most of the load cases and the counterweight does not endanger train traffic in adjacent track.

4.12 The super structure of the crane shall have suitable arrangement for slewing operation like mounting on ball or roller bearing slewing ring. The self-life of the slewing ring shall commensurate with that of the Rail Crane itself.

4.13 The superstructure sides and the tail shall be rigidly connected and suitable locking device shall be provided for locking the super structure in position while moving in train formation.

4.14 An efficient friction brake preferably foot operated for holding the suspended load in any desired position shall be provided in addition to arrangement of lowering the load. Suitable locking arrangement shall also be provided for locking the loads hoisting drum. An efficient hydraulic/mechanic brake system for the hoist motion must be provided, holding the suspended load in any position when the operator return the

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control lever to neutral. The brake must remain closed when the engine is stopped. In addition load lowering must be automatically smooth controlled by the system. Free fall is prohibited.

4.15 The rail-crane shall be equipped with a centralized computer based control and monitoring system which shall monitor the health of Rail Crane working system such as engine (lubricating oil pressure, temperature, rpm etc.), hydraulics (hydraulic pressure in different units, temperature, oil level in tank etc.), pneumatic (pressure of different units), electrical (charging/discharging rate, voltage etc.). All these data should be displayed on a monitor installed in working cabin and there shall be facility to store these data for 100 engine running hours. Minimum storage of 500 GB shall be available for this purpose. Arrangement for providing 3G/4G internet connection for sending data in soft format directly from the computer shall also be available for storage of recorded data. It shall also have facility to interface with Human Machine Interference (HMI)/Display and various other sensors. The data transfer unit should be compatible with the Track Management System (TMS) of Indian Railways.

4.16 In addition to the computer system provided on the machine for its own controls, the machine shall be provided with one additional Industrial quality shockproof & waterproof heavy duty Portable computer (laptop-tough book) for keeping record of overall aspects of working spares management and reporting. The software shall be window based. The hardware shall be sturdy for operation under conditions of shock, vibration, dust, electromagnetic influences from outside and interruption of power supply. The detailed specifications of the laptop are enclosed as Annexure-IV.

5.0 OUT RIGGERS:

5.1 The out rigger of the pull out beam type/swing out type shall be provided with hydraulically power operated mechanism to enable them to be easily extended/slewed or stowed. The number of out riggers shall be such that in one setting of the out riggers or props, a full 3600 swing with load possible. Swing out/pull out beam propping and levelling shall be controlled from the operators cabin or from the ground level.

5.2 The out riggers shall be capable of being mechanically locked in transport mode and hydraulically in working mode. both in closed and extended position effectively.

5.3 There should be provision to operate the out riggers in case of failure of the hydraulic system for which mechanical screw jacks may be provided additionally by an emergency back-up system operated by additional engine operated hydraulic power pack.

5.4 Swing out type hydraulically operated props/out riggers may also be provided subject to they are fitted with robust hinges, stiffer and longer jacks with light weight supports.

6.0 DIESEL ENGINE:

6.1 The machine shall be powered by diesel engine preferably indigenous, with proven

record of service in tropical countries with wide service network in India. Robust construction and low maintenance cost are of particular importance. The manufacturer of the engine shall have acquired quality assurance certification of ISO: 9001. Adequate allowance shall be made for de-rating of diesel engine under the most adverse climatic conditions mentioned in clause no. 2.13. Expected mean life to major parts of the engine for overhauling shall not be less than 8000 engine running hours. Manufacturer of diesel engines, proposed to be provided on Rail Crane, shall

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have proven record of design, manufacture & supply of engines for heavy duty industrial use/locomotives application/track machines application/self-propelled railway rolling stocks (with speed potential as needed for Rail Crane or more) application.

6.2 The supplier shall furnish the details of diesel engine and its controls to assess its conformity with the engines already operating on track machines on Indian Railways. The engine should be of such design/brand which are being manufactured indigenously and/or such designs having after sale service facilities available in India. The supplier should furnish the information regarding agency which will provide after sales service support and availability of spares in India.

6.3 High speed diesel oil to Indian Standard Specification shall be normally used. A minimum fuel capacity sufficient for continuous operation for 8 hrs will be desirable. However, tank capacity in no case shall be of less than 1400 900 litres.

6.4 Sight glass type fuel measuring gauge preferably of full height shall be provided on the fuel tank.

6.5 For starting the engine, storage batteries of well known indigenous make with wide service network in India shall be provided. The engine shall normally be push/pull button start type or key type.

6.6 Since the engine has to work outdoor under extreme dusty conditions, the air intake system shall be designed suitably so as not to allow dust through the air intake system.

6.7 There is a likelihood of dust deposition over the engine body and surrounding area where the lubricants spill over. These shall be easy to access for daily cleaning and routine maintenance. For water cooled engines, the engine cooling radiator shall be easily accessible for regular maintenance like checking the coolant level and topping up of the coolant whenever necessary. Such maintenance activity shall not require the staff to climb up the machine roof with imposition of power block of the OHE. In case, air cooled engines are proposed by the supplier, maintenance equipment for cleaning and maintenance of the air cooling fins shall be provided by the supplier along with the machine.

6.8 The engine parameter monitoring gauges like temperature, rpm, lub.oil pressure shall be direct reading type mounted on the engine backed up by electrical/mechanical gauges in the operator's cabin showing the absolute readings along with safe limits suitably coloured. There shall be audio visual warning (safety mechanism) to the operators in case of any of these parameters exceeding the safe limit and engine will shut down automatically.

6.9 Suitable and rugged mechanism shall be provided to start the prime mover at minimum/no load and gradual loading after the start of the prime move. A fail safe clutch mechanism, if required, may be provided to meet this requirement.

6.10 The engine power take off shall be coupled to the main gear box through a flexible coupling/cardon shaft (propeller shaft). The engine shall be mounted on suitable anti vibration mountings.

6.11 The engine shall have electronic control module (ECM) or similar arrangement for taking out operating parameters on real time basis such as RPM, fuel consumption, load, temperature, pressure and diagnostic data as well as trip and historical data.

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These data shall be displayed and stored on a centralized computer and monitoring system as mentioned in clause no. 4.15. It shall also be possible to transfer these data on USB device through the centralised computer based control.

6.12 In order to adhere to pollution control norms, the diesel engine shall be electronically controlled emmissionized engine with minimum compliance of tier 2 stage/UIC-II/BS-II standard.

6.13 The engine shall be enclosed in a weather protective, sound and dust resistant enclosure to minimize engine noise and to prevent oozing out of oil spills etc. from engine area to the adjacent machine components, hoses, electrical cables fittings as a protection against fire. All doors on the enclosure shall be strategically located in areas as to allow ease of maintenance of the engine and allow good access to and visibility of instruments, controls, engine gauges, etc. Sufficient louvers shall be provided to allow the total engine cooling air requirements used in this application.

7.0 DRIVING MECHANISM:

7.1 The Rail Crane shall be provided with an efficient traction drive system for traction during the operation. The Rail Crane’s driving system shall be through hydrostatically coupled power/transmission with shift arrangement capable of achieving full speeds in travel mode in both the directions. The system should be so designed that all the driving wheels work in synchronization and there is no slippage/skidding of the wheels during the work drive. The driving mechanism for travel drive shall be rugged to perform satisfactorily during the life cycle of the Rail Crane.

7.2 The driving mechanism, in working mode, shall be adequately designed to handle the acceleration and braking forces. Suitable flow divider/throttling arrangement may be provided to equalize the tractive effort amongst different bogies.

7.3 The supplier shall provide the necessary technical details including circuit diagrams and detailed specifications of all electronic/electrical, hydraulic & pneumatic parts to confirm the above requirements.

7.4 To the extent possible hydraulic and pneumatic component/assembly shall be fixed at suitable location preferably on the side frame of the Rail Crane so as to avoid the need of going on top of the Rail Crane for day-to-day maintenance schedules.

7.5 Adequate control equipment including gauges, instrument and safety devices shall be provided for safe and satisfactory operation of the crane. They shall be provided in working and driving cabins near operator’s seat so that they will be within easy reach of the operator.

7.6 The pneumatic circuit shall be provided with air dryer and air lubricator for the smooth working of pneumatic components.

7.7 The Rail Crane shall be equipped with adequate safety circuit such that if any unit/part which may endanger the safety is unlocked, the Rail Crane shall not move during run drive. The indication of locking and unlocking of all units should display in the cabin.

7.8 Onboard system for online filtration and monitoring the quality of hydraulic oil in hydraulic circuit should be provided. The gauge shall clearly indicate that the hydraulic oil is contaminated beyond the permissible limits and requires immediate replacement.

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8.0 SPEEDS-TRACTIVE EFFORT CHARACTERISTICS:

8.1 The tenderer shall submit the Tractive Effort Vs. Speed characteristics for the Rail

Crane and submit the tractive effort requirement calculations for various configurations to assess the engine/transmission adequacy to attain the required speeds.

9.0 COOLING SYSTEM

9.1 The cooling system shall be efficient and designed for a maximum ambient temperature of 55°C. Supplier may note that the machine shall be working under extreme dusty conditions and the cooling mechanism should be maintainable under these conditions.

9.2 Adequate heat transfer arrangement shall be designed and provided so that under extreme heat conditions as mentioned in clause 2.13 above, the system oil temperature does not go beyond the range specified by the supplier.

10.0 SUSPENSION SYSTEM

10.1 The suspension system shall be preferably of two-stage type with suitable spring and damping arrangement. Springs for primary and secondary suspension shall be designed to cater for actual service conditions. Effective measures shall be adopted to minimize the weight transfer while starting, stopping and during runs.

11.0 BRAKES

11.1 The Rail Crane shall be fitted with the compressed air brake system which shall

apply brake equally on all wheels and provision shall be made to connect air brake system of the Rail Crane to that of match truck and coach/wagon/STW hauled by the Rail Crane. Fail safe braking mechanism system shall be provided so that in case of any failure of brake there shall be arrangement of automatic application of brake. The pneumatic parking brake shall also be spring loaded so that in case of drop in pneumatic pressure below certain value the brake will be applied automatically. The brakes shall be protected from ingress of water, grease, oil or other substances which may have an adverse effect on them. The brake shoe lining shall be suitable

for high ambient temperature of 55C. The force required for operating the brake shall not exceed 10 kg at the handle while applying by hand and 20 kg on the pedal, when applied by foot. Mechanical brakes shall also be provided in addition for use as parking.

11.2 Rail Crane shall be equipped with suitable arrangement of braking so that while

attached in train formation as last vehicle, Rail Crane can be braked by traction vehicle having compressed air braking system. In addition the Rail Crane shall be equipped with suitable air brake system in the driving cabins so that the attached wagon or coach in case of any emergency for attaching one coach or one wagon they can be braked by Rail Crane. while being hauled by the Rail Crane can be braked.

11.3 There shall be provision of emergency brake application in working mode by means of emergency buttons on each corner of the chassis. The brake shall apply smoothly to avoid dangerous situations with suspended loads. As well as provision of emergency brake application shall be provided while the Rail crane is coupled with one coach/wagon (attached only in emergency) using the compressed air in the Rail

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Crane either travelling alone or coupled with the coach/wagons/STW, in addition to the normal braking system of the Rail Crane. In towing mode, the emergency braking distance (EBD) of the Rail Crane on the Indian Railways track at the maximum designed speed on a level track shall not be more than 600 m. In this regard necessary design calculations for the braking effort and EBD at the maximum design speed of the Rail Crane on level track & at falling grade of 1 in 33 should be provided by the supplier. Brake design details are to be submitted as per Annexure V.

11.4 Clearly visible brake lights shall be provided at both the ends of the Rail Crane as well as on Match Truck, which will be automatically operated when brake is applied and switched off when brake is released. This will be required to alert the operator of Rail Crane following this Rail Crane when the Rail Cranes are working in groups. In working mode clearly visible brake lights shall be provided at the rear side of the superstructure to alert other vehicle operators behind the crane. On each end of the chassis a clearly visible strobe light must be installed which starts flashing when the crane is moving. Additionally, an audible sound shall warn workers in the area.

12.0 HORN, HOOTER AND SAFETY SWITCHES

12.1 The Rail Crane shall be provided with dual tone (low tone & high tone)

electric/pneumatic horns facing outwards at each end of the Rail Crane at suitable locations for use during travelling to warn the workmen of any impending danger. Control shall be provided in close proximity to the driver permitting the driver to operate either horn individually or both horns simultaneously. The horns shall be distinctly audible from a distance of at-least 400 m from the Rail Crane and shall produce sound of 120-125 dB at a distance of 5 m from horn (source of sound). The higher tone horn shall have fundamental frequency of 370 ±15 hertz. These horns shall be operated by means of push buttons provided in the cabins.

12.2 Adequate numbers of safety stop switches shall be provided all around so that in case

of any danger to worker as well as hitting of any obstructions like signal post/OHE mast etc. by any part of the crane during work, so that the operator can be warned or the Rail Crane can be stopped immediately.

12.3 Safety equipment like jack, pullers, tirfor and other such equipments specific to the Rail Crane for restoring failed units of the Rail Crane during working shall be provided on the Rail Crane.

12.4 Rail Crane shall be provided with emergency backup system to wind up the Rail Crane in the event of failure of prime mover or power transmission system of the Rail Crane. The emergency backup system shall be able to be operated manually also.

12.5 Pneumatically/electrically operated hooters capable of producing intensity of sound between 105-110 dB at a distance of 5 m (when measured in still air in a closed room) and variation in intensity of sound shall not be more than 5 dB. The hooter shall be provided facing outwards at each end of the Rail Crane at suitable locations, operated by means of push buttons provided in the cabins to warn the staff working on/around the Rail Crane about approaching train on adjoining track. Additionally switches for such hooter shall be provided in the Rail Crane frame and near the both side exit gates so that it can be operated by staff present at work site near the Rail Crane. The hooter shall also be operated by remote switch at a distance of at least 300 m from the hooter.

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12.6 In addition, separate electric horns with push bottom type switches shall be provided at suitable locations in all cabin(s) and on Rail Crane body for communication between the Rail Crane staff about infringement/malfunctioning or any other trouble.

13.0 CHASSIS AND UNDERFRAME

13.1 The chassis shall be fabricated from standard welded steel sections and of steel sheets, so as to permit transportation of the Rail Crane in train formation without endangering safety of the train. The under-frame shall be constructed with rolled steel section and/or plates shall be designed to withstand a horizontal squeeze load of 102 t at CBC rear stops or 51 t at each buffing point without any permanent distortion. The under-frame shall be sufficiently robust for safe travel of the rail crane in train formation and not necessarily as the last vehicle.

13.2 There shall be provision of properly exhibited/conspicuous jacking and lifting points on the Rail Crane under-frame for helping in quick handling of the crane in case of derailment/accident as well as during maintenance at workshop. The jacking and lifting points shall be obstruction free and easily accessible, so that jacks can be fitted/placed conveniently.

14.0 HOOKS AND BUFFERS

14.1 The Rail Crane shall be fitted with transition coupling as per specification no. RDSO/2009/CG-22 with latest revision along with side buffers to RDSO drawing no. RDSO/SK-98145 with latest alteration on both ends for coupling it with coach or other vehicles while running in train formation as last vehicle.

15.0 TOOLS AND INSTRUCTIONS MANUALS

15.1 Each Rail Crane shall be supplied with a complete kit of tools required by the operator in emergency and for normal working of the Rail Crane. The tenderer shall along with his offer submit the list of tools to be supplied along with each Rail Crane. The list of tools to be provided shall also include all tools necessary for maintenance and repair of the entire Rail Crane including specialized equipment. All special tools shall be listed and catalogued illustrating the method of application. The tenderer shall along with his offer submit the list of tools to be supplied along with each Rail Crane. The list can be modified to suit the purchaser’s requirement, while examining the offer.

15.2 Detailed operating manual, maintenance, service manual and user manual indicating

capabilities of Rail Crane shall be specifically prepared in English language and four hard & soft copies of these shall be supplied with each Rail Crane.

15.3 The manufacturer shall also supply circuit diagrams in hard and soft copies of electrical, electronic, hydraulic, and pneumatic circuits used on the Rail Crane. Trouble shooting diagram/table shall also be supplied. In additions, the supplier shall provide dimensional drawings with material description of items like rubber seals, washers, springs, bushes, metallic pins etc. and main features such as type and discharge etc. of items like hydraulic pumps, motors and such other bought out components/assemblies shall be furnished by the tenderer. These shall be specially prepared in English language and four in hard and soft copies of these shall be provided with each Rail Crane.

15.4 While offering the Rail Crane for first inspection, the supplier shall submit one copy of complete technical literature in English language including operation, service and field maintenance manuals/instructions, complete electrical, hydraulic and pneumatic

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circuit diagrams, trouble shooting charts, components drawings/description and other relevant technical details for keeping as a reference document for the inspecting officer.

15.5 The tenderer shall along with his offer, submit the list of tools, manuals, circuit diagrams and other technical literature/drawings in English language to be supplied along with each Rail Crane as above, for operation, servicing, maintenance, assembly overhauling, periodic overhauling and troubleshooting guides/manuals. The list can be modified to suit the purchaser’s requirement, while examining the offer.

15.6 One portable diesel operated D.C. welding plant (with the provision of auxiliary output of minimum 2.5 KW, 230 V AC for lighting) of reputed make (preferably made in India) with a minimum 5 KVA capacity capable of welding up to 5 mm (dia) electrode at 60% duty cycle shall be supplied. Sufficient cable or lead shall be provided with the Rail Crane of welding plant for day to day repairing of Rail Crane and its wearing parts. The diesel tank capacity shall be not less than 15 liters.

15.7 One set of all the manuals and diagrams in hard and soft copies prepared in English language shall also be sent to the Principal/IRTMTC, Allahabad, one set to ED/TMM, RDSO, Lucknow, one set to DTK (MC)/Railway Board and one set to Director/IRICEN/Pune along with supply of first Rail Crane of similar group. In case, there is any subsequent amendment in above documents based on field performance, the amendment/amended documents shall also be sent to above mentioned authorities.

15.8 The firm shall provide detailed technical drawings and specifications of wheels and axles used in the Rail Crane. The above details shall be provided in four sets with each Rail Crane.

15.9 A draft copy of all documents to be supplied with the Rail Crane shall be sent 3 months in advance of inspection of the first Rail Crane to RDSO for their review regarding adequacy and manner of detailing. Necessary modifications and further detailing as per RDSO’s comments shall be carried out and compliance shall be reported to RDSO as well as the Inspecting officer of the first Rail Crane.

16.0 HEAD LIGHT, FLASHER LIGHT, MARKER LIGHT AND OTHER LIGHTING

ARRANGEMENTS

16.1 The electrical equipment to be provided shall conform to relevant standard specifications and shall be suitable for Indian climatic conditions. The Rail Crane shall be equipped with twin beam LED headlight assembly conforming to RDSO

specification no. RDSO/2017/EL/SPEC/0134 (Rev-0) with latest amendment to ensuring a light intensity of 3.2 lux at ground level at track centre at a distance of 305 m away on a clear dark night, at each end and with two front and rear parking lights, which can be switched to red or white according to the direction of the travel. Powerful swivelling floodlights shall also be provided to illuminate the working area sufficiently bright for efficient working during night. In addition minimum eight power point locations (24 volt DC/15 amp socket) shall be provided on outside frame of the Rail Crane two in front, two in rear and two on both sides for providing lighting arrangements during night working. Specification for DC-DC converter for electric loco/diesel electric loco no. ELRS/SPEC/DC-DC converter/0021, (rev-1, Sept’ 2004 or latest).

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16.2 The amber colour LED based flasher lights producing not less than 500 lux at 1 m and 55 lux at 3 m in line measurement in axial direction from flasher light to RDSO Spec No. ELRS/SPEC/LFL/0017 (Rev-1) of Sept-2004 or latest shall be provided at both ends in the Rail Crane to give indication to the train arriving on other line about any impending danger.

16.3 The Rail Crane shall be provided with Marker light to RDSO specification no. ELRS/SPEC/PR/0022, (Rev-1) October’ 2004 or latest.

17.0 SPARE PARTS

17.1 The expected life of the components/spare parts shall be advised along with their condemning limits. The Rail Crane shall be supplied with necessary spare parts for the operation and maintenance of the Rail Crane for a period of two years. The spare parts required shall be detailed in a separate list indicating description, part number, quantity and whether imported or indigenous.

17.2 The manufacturer shall be responsible for the subsequent availability of spare parts

to ensure trouble free service for the life of the Rail Crane (25 years). It is preferred that the spares shall be stored in India and will be available at short notice say maximum within a month.

17.3 For indigenous parts and bought out components and assemblies, the source (original equipment manufacturer’s reference and part no.) and other relevant technical details shall be supplied while offering the first Rail Crane for inspection.

18.0 OPTIONAL EQUIPMENT

18.1 Tenderer is expected to quote for optional equipment if any separately for each item

giving the advantages/functions of such optional equipment. Tenderer shall also indicate whether such equipment are already in use on Rail Crane elsewhere indicating the user Railways system.

19.0 CABINS

19.1 The Rail Crane shall be equipped with fully enclosed, sound and heat insulated cabin with safety glass windows. In view of the high ambient temperature prevailing in India, special attention shall be paid to free circulation of air and ventilation in the driver’s cabin. It shall be possible to have a clear view of the track ahead while driving the Rail Crane from the cabin. The cabin layout shall be such that the operating staffs has full view on both the sides before leaving the Rail Crane, to avoid any danger to them from trains on the adjacent tracks. The design of drivers cab shall be as per UIC-651.

19.2 The cabin of the Rail Crane shall be air-conditioned for dust free atmosphere. The air-conditioning provided shall be of robust industrial design capable of operating in highly dust laden environment. The air-conditioning units shall not be roof mounted and under-frame mounted for safety and maintenance purpose. However the electronic equipment shall be so designed that they shall be able to work without air-conditioning under the climatic conditions as described in clause 2.13 above.

19.3 The operator’s cabin shall be ergonomically designed. The gauges, panels and controls shall be suitably located in the operator’s cabin so that they can be observed by the operator without undue fatigue. All control levers, foot brakes etc., shall be

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placed in a convenient location in the operator’s cab within easy reach of the operator. The operator shall have a full view of the working area from the operating seat to have a full control over the work.

19.4 Screen wiper preferably operated by compressed air or electrically operated shall be provided on the wind screens.

19.5 Suitable number of fire extinguisher (dry chemical type) shall be provided in all the cabins. A semi-automatic fire extinguishing system shall be installed in engine and machinery houses. Manual fire extinguishers are placed outside on the crane and a small size in the operators’ cabin. The chemicals used for extinguishing fire by such fire extinguishers shall not chemically react with electronic equipment/components, PCBs, cables etc.

19.6 The Rail Crane or match truck shall be provided with well designed space for keeping the tools and spares required for onsite repair of the Rail Crane to attend the breakdowns and other working requirements.

19.7 Necessary inter-communication system shall be provided inter-connecting the cabin with ground working staff and shall be so oriented that the operator, seating on the seat of cabins, can easily hear distinctly the conversation.

19.8 The Rail Crane shall be equipped with speed indicator and recording equipment of range between 0-120 kmph for recording the speed of the Rail Crane in real time basis. The equipment shall conform to RDSO specification no. MP-0-0.3700-07, Rev-07, Aug’ 17 or latest. The recorded data shall be retrievable on computer through memory card/pen drive. It shall be provided in the driving cabin at suitable place and recording system shall have sufficient memory to keep the speed record of minimum 15 days which should always be stored for retrieving as per requirement.

19.9 The electric supply in the cabin for operation of electrical instruments, gauges etc. shall not be more than of 110 V.

19.10 For prevention of fire in the machine suitable materials shall be used for construction of interiors as well as exteriors of the cabin and for machine components. Proper design layout, protective device and prevention measures for outbreak of fire shall be ensured. For fire prevention “Code of Practice for Prevention of Fires on DMUs” conforming document no. CMI-K 402(Rev-1) with latest amendments shall be suitably followed as guidelines. The tenderer shall submit his fire protection concept with the offer in compliance to above code/ISO EN 14033”Track Machinery”.

20.0 MAKER’S TEST CERTIFICATE

20.1 Copies of maker’s certificate guaranteeing the performance of the Rail Crane shall be supplied in duplicate along with the delivery of each Rail Crane.

21.0 OPERATORS

21.1 The number of operators and allied staff for working of the Rail Crane under normal

condition shall be indicated, specifying their duties and minimum qualifications.

22.0 INSPECTION OF THE MACHINE

22.1 While inspecting the Rail Crane before dispatch from the supplier’s premises, the inspecting officer shall verify the conformity of the Rail Crane with respect to

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individual specification as above. The crane’s conformity/non-conformity issue in respect to each item shall be jointly recorded before issue of the inspection certificate and approval for dispatch of the Rail Crane as per Annexure–VIII enclosed.

22.2 Following arrangements shall be made by the supplier/manufacturer at the inspection

premises for carrying out inspection of the Rail Crane by inspecting officials:

• The Rail crane to be stabled on straight & level BG track. The length of the track shall be at least 10 m more than buffer to buffer length of Rail Crane.

• In order to check maximum moving dimensions in cross section, a sturdy frame of Indian Railways max moving dimensions shall be provided by the manufacturer and passed over the machine holding it perpendicular to track, centre aligned with track centre. Adequate arrangements shall be made to the satisfaction of inspecting official.

22.3 The following documents shall be provided to the Inspecting Officer at least 30 days in advance of the date of inspection.

i) One copy of complete technical literature mentioned in clause 15, in English

language, including operation, service and field maintenance manuals/instructions and complete electrical, hydraulic and pneumatic circuit diagrams, trouble shooting charts, component drawings/description and other relevant technical details as a reference documents in soft & hard copies for the inspecting officer.

ii) Cross section of the machine super imposed on Indian Railways maximum moving dimensions envelope shall be provided to inspecting officer (IO) in advance.

iii) Clause by clause comments of the manufacturer need to be furnished with the offer, become part of a contract and shall to be sent to Inspecting Officer (IO) in advance for his review. Comments should state manufacturer’s conformity of compliance of each of the requirement stated in each clause, elaborating where necessary the details/manner in which the requirement has been complied. The pro forma for the clause wise comments is given below:

Clause no. Clause Comments of Supplier/Manufacturer

Comments of Inspecting officer

iv) Manufacturer’s internal quality inspection report of the machine.

v) Manufacturer’s quality certificate and/or test reports for bought out

assemblies/sub-assemblies shall be provided to Inspecting Officer (IO), containing serial number wherever applicable.

vi) Draft inspection report shall be prepared by the manufacturer, containing all Annexure mentioned at clause 22.4.

vii) Details of arrangements made for checking maximum moving dimensions for his approval.

Supplier will incorporate amendments/further clarification in the above documents to the satisfaction of the Inspecting Officer (IO) keeping in view the Inspecting Officer’s comments, if any.

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22.4 List of documents to be annexed in the draft Inspection report shall include:

i) Maker’s Test Certificate. ii) Manufacturer’s Internal Quality Inspection Report. iii) Quality Certificates of Bought out assemblies/sub-assemblies. iv) Cross section of the machine super imposed on the Indian Railways

maximum moving dimensions (IR MMD). v) Vogel’s diagram. vi) List of spare parts shall be dispatched along with the machine. vii) List of tools shall be dispatched along with the machine. viii) List of manuals, drawings, spare parts catalogues, etc. shall be dispatched

along with the machine, duly indicating the number of sets of each. ix) Manufacturer’s certificate on standard followed for design of wheels and axles

against clause 2.9 to 2.11.

These above documents in soft & hard copies shall be part of final inspection report.

23.0 ACCEPTANCE TEST

23.1 In addition to verification of the various items of specifications covered earlier, the following tests shall be carried out in India at the purchaser’s premises by the purchaser’s nominee at the time of the commissioning of the Rail Crane. The pre-commissioning test shall be completed and the Rail Crane shall be commissioned within 90 days of its arrival at the premises of the final consignee.

23.2 Dimensional check of loading gauge, i.e., maximum moving dimensions, buffer heights, clearances, length of machines, bogie distance and clearance on curves etc.

23.3 Testing for negotiability of 100 curves and 1 in 8.5 turnouts.

23.4 Construction and engineering of the Rail Crane and its ability to perform all the functions as laid down in the specifications above.

23.5 Actual output and performance tests – Refer Clause 4.0 :

These tests shall be conducted under field conditions on Indian Railways. An electrified section shall be chosen for the tests.

The general conditions of the tests shall be as follows: i) The Rail Crane crew shall be either trained personnel of Indian Railways or the

staff of the supplier. ii) Dry weather, ambient temperature between -50C to 550C. iii) Straight track or curve of radius minimum up to 1000 m. iv) Straight track with gradients up to 5 per thousand. v) Rails and sleepers in good conditions and properly fastened. vi) Concrete sleepers. vii) The rails of the Turnout, to be renewed shall be securely fastened with the

sleepers.

23.6 Actual test to be conducted: i) Loading of Turnout assembly as a whole or in segment as per the

accommodating length of the transporting wagon at assembling site/workshop/depot.

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ii) Hauling the loaded wagon(s) to work site.

iii) Lifting the old Turn out assembly as a whole or in segment placing the same

temporarily on a suitable place at the vicinity of the worksite.

iv) Lifting the new Turn out assembly from wagon and laying it in the place of old Turn out.

v) Lifting the old Turn out assembly and loading the same on the wagon.

vi) The setting up time and winding up time of the Rail Crane as described in the

specifications elsewhere shall be measured and the total time taken by the two operations of setting up and winding up of the Rail Crane together shall not exceed 20 minutes.

24.0 Should any modification be found necessary as a result of the tests, the same shall

be carried out by the supplier at his own expenses.

25.0 SPEED CERTIFICATE

25.1 PROVISIONAL SPEED CERTIFICATE

Whenever a new rolling stock is introduced in Indian Railways, a provisional speed certificate is issued by RDSO of Indian Railways based at Lucknow, based on certain design parameters of the machine. Final speed certificate of the machine shall be given after conducting detailed oscillation trials of the machine, which shall be a time taking process. Therefore, issue of provisional speed certificate for the machine becomes a necessity and based on the same the approval of running of the machine on Indian Railways track is taken from Commissioner of Railways Safety.

For issue of provisional speed certificate, the following actions are required to be taken by the suppliers.

a) Current suppliers, whose models are approved :

The supplier shall give details of the model, year of introduction in Indian Railways, details of speed certificate issued etc. The supplier shall certify that no change has taken place in the model being offered with respect to design of under frame i.e. suspension system/arrangement, wheel & axle assembly, bogie, braking arrangement loading pattern of the machine etc. and the distribution of axle loads, lateral forces, un-sprung mass and braking force coming on rail is the same. If, there is any change in above respect, the action shall be taken as detailed in clause (b) below:

b) Current suppliers, whose models are not approved/or new :

As soon as the supplier completes the design of the machine as per specifications, the technical details as per Annexure (VI & VII) which in no case shall be more than six months from signing of contract, shall be supplied to Track Machine and Monitoring Directorate of RDSO for processing of provisional speed certificate for the machine so that it can be permitted to move on track on case-to-case basis. More technical details (other than mentioned in Annexure VI & VII) can also be asked for issue of provisional speed certificate for the machine. The firm will also submit the technical details as per pro-forma placed at Annexure-IX for track vehicle dynamic simulation. The supplier shall submit the track vehicle simulation report.

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c) New suppliers, whose models are new :

The technical details shall be supplied as detailed in clause (b) above.

25.2 Final Speed Certificate:

Final speed certificate of the vehicle shall be given after conducting detailed oscillation trials of the machine. For this purpose Railways shall conduct running speed tests on the Indian Railways main line track on one of the machines supplied to them preferably with in warranty, in accordance with procedure outlined in Annexure-X with the machine running up to speed 10% higher than the maximum speed mentioned in clause 2.14 above.

26.0 TRAINING & SERVICE ENGINEERS

26.1 The supplier shall provide at his own expense the services of competent engineers

during the warrantee period for warrantee related issues. The service engineers shall be available for the commissioning of the Rail Crane for regular service. E-Learning courses module shall be arranged for imparting training to Railways operators. In addition the service engineer shall provide hands on training to Railway staff in calibration, operation, repairing and maintenance of the Rail Crane in field to make them fully conversant with the machine. The engineers shall also advise the Railways on appropriate maintenance, testing, operating, repair and staff training facilities that are necessary for the efficient performance of the Rail Crane.

27.0 WARRANTY

27.1 The Rail Crane shall be warranted for 18 months from the date of commissioning and

proving test of Rail Crane or 24 months from date of delivery at ultimate destination in India whichever shall be earlier.

Should any design modification be made in any part of the Rail Crane offered, the warranty period of 18 months would commence from the date of commissioning and proving test of Rail Crane for the purpose of that part and those parts which may get damaged due to defects in the new replaced part. The cost of such modification shall be borne by the supplier.

28.0 MARKING & COLOUR OF MACHINE

28.1 The machine body shall be painted in golden yellow colour of Indian Standard colour code of 356 conforming to IS: 5. The exterior painting shall be polyurethane binder based conforming to RDSO Specification No. M&C/PCN/100/2013 (Specification for Epoxy cum Polyurethane Painting System–Two packs for the Exterior Painting of Railway Coaches, Diesel and Electric Locomotives and other Industrial Applications) or conforming to ISO 12944.

28.2 Following shall be written on the machine at appropriate location in English & Hindi

as per direction of Indian Railways official.

i) India Railways logo of height between 300 mm to 600 mm as suitable on all four faces of the machine.

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ii) On both side faces and below the Indian Railways logo, the text “ INDIAN RAILWAYS” shall be written in bold and in black colour of size equal to or slightly smaller than the size of logo but of size not less than 250 mm.

iii) Below the text “INDIAN RAILWAYS” mentioned above, machine model and manufacturing year shall be written in black colour and in letter of size less than the size in which Indian Railways is written but not less than 200 mm in any case.

iv) If required, the manufacturer’s name may be written in size not more than 150 mm and shall not be at more than four locations. Also the manufacturer’s logo may be provided at not more than two locations and shall be of size less than 200 mm.

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Annexure-I

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6°42'35"

28588 OVER TNC

32739 OVER BACK LEG OF X-ING

39338VER END OF X-ING SLEEPER

1280013400

SL 2

2

(L=

3100 m

m)

51582 OVER BACK LEG OF X-ING 59992 OVER END OF X-ING SLEEPER

844 11200 35720

SL 1

01

( L=

51

00

mm

)

Total weight (approx.) 65.02t Max length of Sleeper 5100 mm Max length of assembly 59992 mm

HEEL

3°34'35"

1: 16 T/O WITH 11200 mm O/R , C/S & CMS X-ING 1673 mm for 60 KG ON PSC SLEEPERS

TNC

Annexure-II

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Annexure-III

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Annexure-IV

Specifications of Heavy duty Industrial Quality Water proof & shock proof

Laptop

CPU Intel Core i-5-7440HQ processor, speed 2.8 GHz up to 3.8

GHz or higher version

Operating System Latest windows 10 professional or higher version

RAM 8 GB DDR4 or more and expandable minimum 32 GB

Storage Shock protected removable HDD SATA 500 GB expandable up to 1 TB

Display Minimum 15.6” high definition LED/TFT/LCD or better with

sunlight readable display, anti reflective and anti glare

treatment.

Keyboard LED Backlit 61 key QWERTY keyboard with integrated

numeric pad. Touchpad with vertical scrolling support.

Wireless Integrated Gobi 2000 mobile broadband or better, Bluetooth V

4.0 or better.

Durability features Product shall be fully rugged, durable and meet the latest MIL

standard. Moisture/water and dust resistant screen, Key board

and touch pad.

Pre Loaded Software Antivirus software for 18 months validity.

Microsoft office 2007 or latest complete bundle (Licensed copy

with CD backup)

Power supply Long life Li-ion battery, minimum 8700 m AH.

Warranty 5-year warranty

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Annexure-V BRAKE DESIGN DETAILS OF THE MACHINE FOR

CALCULATION OF EMERGENCY BRAKING DISTANCE

Tare & gross weight of the machine in Kilograms

Brake power in Kilograms

Type of Brake blocks

Brake block area in square centimeters

Brake Rigging Diagram

Type of Brake system

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Annexure-VI

Particulars Required in Respect of the Rolling Stock under Consideration

1. A diagram showing elevation salient dimensions : a) Wheel spacing, Wheel diameter, bogie centres, and axle load. I. Overall length of the vehicle : II. Length over head stock : III. Length over buffers : IV. Distance apart for center of buffers : V. Max./Min. height of centers of buffers(above rail level) : b) I. Wheel base : II. Axle load (max) : III. Bogie Centres : 2. Wheel dimension : I. New : II. Worn out : 3. I. Tread and flange profile of the wheel indicating clearly

whether it is Indian Railways standard profile or differs from standard flange profile.

:

II. Wheel gauge dimension (back to back of tyre flange).

:

4. Whether the stock is designed to be used as a general purpose or in a closed circuit in specified sections under defined conditions.

:

5. Maximum design speed : I. Own Power : II. In train formation 6. Unsprung weight per axle in tonnes I. Driving axle : II. Running axle : 7. Sprung weight per axle in tonnes I. Driving axle : II. Running axle : 8. Stiffness of suspension coil spring/Megi spring 9. Expected lateral force in tonnes per axle At maximum design speed. : 10. Increase in the impact load during motion(Dynamic Augment) : 11. Method of operation - Whether single only or coupling together is possible. If coupling is possible,

the number which can be coupled and what is trailing load. :

12. Maximum tractive effort at start and at the speed of operation - I. At working drive at start : at operation speed : II. At transfer drive at start :

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at maximum speed : 13. Maximum braking force coming on to the rails per wheel at working axle : at transfer axle : 14. Drawing indicating suspension arrangement details of bogie and axle. : 15. Height of centre of gravity from rail level. : 16. Height of floor from rail level. : 17. Type of coupler provided -Indian Railways Standard I. Coupling : II. Buffer : 18. Any infringement to the moving dimensions : (Sketch provided in the Indian Railways Standard Schedule of Dimensions

– Chapter IV (A)).

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Annexure-VII

Following information as detailed below is also required along with the information required for processing the case for issue of provisional speed certificate for new vehicles

Name of the machine ________________ Model________________

Sr.No. Item

1. a) Brake System details

b) Gross Braking Ratio

2. Brake rigging arrangement drawing and calculation of braking force

3. Maximum Braking Effort. at start and at the speed of operation -

a) At working drive at start :

at operation speed :

b) At transfer drive

at start :

at maximum speed :

4. Characteristics of springs used in suspension indicating free height, working height,

dynamic range, stiffness and locations etc.

5. Characteristics of the dampers if used, and over all damping factors and locations of

dampers.

Calculation of the following frequency of the vehicle to be attached :-

i) Bouncing ii) Pitching iii) Rolling

Wave length of free axle and bogie

6. Write up and salient design calculation on suspension system, type of suspension-

whether it is of coil suspension with or without dampers and laminated bearing springs

and double link suspension.

7. What are lateral clearance of axle box/worn wheel flange/rail and other locations for the

negotiability of the vehicle on curve and turn out (enclose Vogel’s diagram for negotiability

on maximum degree of curve and turn out permitted on Indian Railways) of new and worn

out wheel.

8. Wheel and axle assembly drawings.

9. Calculation for flange force.

10. Technical specifications of Vehicle supplied.

11. Calculation of natural frequency.

12. Calculation of spring characteristics and critical speed of the vehicle.

13. Simulation result showing ride index, lateral force and acceleration results.

14. A certificate regarding the speed of the vehicle for which it has been designed.

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Annexure-VIII

INSPECTION CERTIFICATE

CERTIFICATE OF INSPECTION OF RAIL CRANE (MODEL No...........................................) BY INSPECTING OFFICIAL AND APPROVAL FOR DESPATCH OF RAIL CRANE. (STRIKE OUT WHICHEVER NOT APPLICABLE)

This is to certify that I have inspected the RAIL CRANE_______________________________bearing Sr.No._________________ from (date)_________to__________at (Place)________________ for its conformity/non-conformity with respect to the laid down Technical Specifications in contract Agreement No.____________________dated_______ between President of India through Executive Director/Railway Board and M/s. (Name of Supplier) ___________________________ ___________________________________. The detailed inspection note regarding its conformity/non-conformity to the laid specifications is enclosed along with this certificate. It is observed that (strike out whichever is not applicable):-

• The Rail Crane conforms to all the laid down specifications.

• The Rail Crane conforms to all the laid down specifications except those at Sl. No.________________________.

• The above deviations are minor/major affecting/not affecting the performance of the equipment in substantial way. The following T and P/manuals/drawings are to be supplied along with the machine:

1. __________________________ 2. __________________________ 3. __________________________ Based on the above, the RAIL CRANE is certified/not certified to be conforming to the specifications. The RAIL CRANE is approved/not approved for dispatch to__________________(Consignee) Indian Railways.

SIGNATURE AND DATE For M/s._________________________ INSPECTING OFFICIAL _______________________

(NAME AND DESIGNATION)

for and on Behalf of President of India

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Annexure-IX

Machine details required for simulation of machine on Track- vehicle dynamic simulation software

S.No.

Component’s Name

Parameters required

C.G. of component in x, y, z direction from rail level in mm (reference point 1st axle)

Mass in kg and mass moment of inertias in kg. m2 of component in three dimension space about their C.G.

X Y Z Mass Ixx Iyy Izz

1. Super structure with vehicle frame (Machine structure kept on secondary suspension of front and rear bogie)

2. Front Bogie frame including brake rigging

3. Rear Bogie frame including brake rigging

4. Transmission system device (hydraulic. Mechanical or electrical traction motors

5. Wheel axle set including axle boxes which constitute the unsprung mass

6. Mass of Items included in unsprung mass partially or fully along with their name per axle

1 2 3 4 5 6 Total unsprung mass in tonnes

7. Total weight of components in tonnes

Front bogie full assembly

Central bogie full assembly

Rear bogie full assembly

Machine frame full structure

Full weight of vehicle (All bogies + vehicle car body or super structure)

8. Suspension stiffness details in kg/mm

Primary suspension element stiffness per axle box between bogie and axle box

Secondary suspension element stiffness per side between bogie and machine frame

Vertical stiff Lateral stiff Longitudinal stiff Vertical stiff

Lateral stiff Longitudinal stiff

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9. Damping force details (If hydraulic damper used give there rating force per meter/second)

10. Clearance in mm or radian provided for motion between bogie frame and machine frame for relative motion (motion stopper)

Vertical direction

Lateral direction

Longitudinal direction

Rotation about vertical axis

Rotation about Lateral axis

Rotation about Longitudinal axis

11. Detail of location of suspension elements

Detail of location of suspension springs and dampers and shock absorbers with support drawing

Detail of location of suspension springs and dampers and shock absorbers with support drawing

12. Details of centre pivot arrangement working and location

Provide detail arrangement drawing and description

13. Set of drawings and design description

Concerning with general arrangement of vehicle, bogie general arrangement, suspension arrangement details, suspension clearances drawing, detail written description of configuration and loading pattern accompanies design particular of vehicle bogie.

238061/2020/O/o PED/TMM/RDSO203


Annexure-X ACCEPTANCE CRITERIA DURING OSCILLATION TRIALS

1. The speed potential of the Rail Crane offered by the firm should be established based upon oscillation trials conducted in India. The tests will be conducted at speed usually 10% higher than the maximum speed potential indicated by the firm for the machine under consideration and the following criteria satisfy for the same. For conducting the tests, a section of mainline track will be selected over which there is no temporary speed restrictions and which is considered by the Railway as being in a generally run down condition for mainline standards, but without speed restrictions. The vehicle will be tested generally for new and worn wheel clearance conditions and where relevant for operation in the forward and backward directions. The vehicle selected for tests will be one in average condition for normal maintenance.

2. The criteria applicable for establishing speed potential will be as follows:

a. A lateral force lasting over a length more than 2 metres should not exceed the Prud-Homme’s limit of K(1 + P/3) tonnes. Where P is the axle load in tonnes, K=0.85 for wooden sleepers and K= 1 for concrete sleepers.

b. Isolated peak values exceeding the above limit are permissible provided the record shows establishing characteristics of the vehicle subsequent to the disturbances.

c. A derailment coefficient should be worked out in the form of ratio between the lateral force (Hy) and the wheel load (Q) continuously over a period of 1/20th second, the value Hy/Q shall not exceed 1.

d. The values of acceleration recorded in the cab at location as near as possible to the bogie pivot (as near as possible to axle in case of four wheelers) shall be limited to 0.55 g both in vertical and lateral directions. The peak values up to 0.60 g may be permitted if the records do not indicate a resonant tendency in the region of peak value.

e. In the case of such vehicles where measurement of forces is not possible, the evaluation shall be in terms of ride index based on the accelerations measured as detailed in Para 2 (d) above which shall not be greater than 4.5 but a limit of 4.25 is preferred.

f. A general indication of stable running characteristics of the vehicle as evidenced by the movements of the bogie in straight and curved track and lateral force and derailment coefficient of accelerations as the case may be.

238061/2020/O/o PED/TMM/RDSO204

technical specification of rail borne telescopic crane for

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